A system configured to test battery cells. The system includes: a movable platform; a plurality of test stations movable by the movable platform, each one of the plurality of test stations configured to cooperate with a pallet on which the battery cells are seated, each one of the plurality of test stations including probes that are movable into cooperation with the battery cells and configured to inject gas into each one of the battery cells; and a camera adjacent to the movable platform and configured to detect leakage of the gas out from within any of the battery cells.
Legal claims defining the scope of protection, as filed with the USPTO.
a movable platform; a plurality of test stations movable by the movable platform, each one of the plurality of test stations configured to cooperate with a pallet on which the battery cells are seated, each one of the plurality of test stations including probes that are movable into cooperation with the battery cells and configured to inject gas into each one of the battery cells; and a camera adjacent to the movable platform and configured to detect leakage of the gas out from within any of the battery cells. . A system configured to test battery cells, the system comprising:
claim 1 . The system of, wherein the movable platform is circular.
claim 1 . The system of, further comprising an input conveyor line configured to transport the pallet to the movable platform and an output conveyor line configured to transport the pallet away from the movable platform after the battery cells are scanned by the camera.
claim 1 . The system of, wherein each one of the plurality of test stations includes an entry gate and an exit gate spaced apart to accommodate the pallet therebetween, each one of the entry gate and the exit gate is configured to be opened and closed to permit transport of the pallet to and from the plurality of test stations.
claim 1 . The system of, wherein the probes are movable vertically.
claim 1 . The system of, wherein the gas is carbon dioxide.
claim 1 . The system of, wherein the camera is an infrared camera including a filter configured to block transmission of infrared radiation outside of a wavelength range of 4-5 μm.
claim 1 . The system of, wherein each one of the plurality of test stations further includes a back plate on a side of the pallet opposite to the camera, the back plate configured as a background radiation source for the camera and configured to be heated to a temperature of 10° C.-30° C. greater than an ambient temperature.
claim 1 . The system of, further comprising a pump configured to pump the gas through the probes to the battery cells at a pressure of no greater than 1 psi.
claim 1 the gas injected into the battery cells is a first gas injected prior to addition of an electrolyte within the battery cells; and the camera is further configured to detect leakage of a second gas out from within any of the battery cells subsequent to installation of an anode, a cathode, and an electrolyte, the second gas is different from the first gas. . The system of, wherein:
claim 10 . The system of, wherein the camera is an infrared camera including a filter configured to block transmission of infrared radiation outside of a wavelength range of 5-12 μm to detect the second gas.
claim 1 the movable platform is configured to move a first station of the plurality of test stations to a first position at which a first pallet with a first group of the battery cells thereon is coupled to the first station between an entry gate and an exit gate of the first station, the battery cells devoid of an electrolyte; the movable platform is configured to move the first station to a second position at which a carrier is configured to move the probes into contact with the battery cells and a pump is configured to pump gas through the probes into the battery cells; the movable platform is configured to move the first station to a third position at which the probes remain in contact with the battery cells and the battery cells remain filled with the gas; the movable platform is configured to move the first station to a fourth position at which the camera is configured to scan the battery cells for leakage of the gas out from within the battery cells, and the carrier is configured move the probes away from contacting the battery cells after the camera has scanned the battery cells for leakage of the gas; the movable platform is configured to move the first station to a fifth position at which the exit gate is configured to open to permit the pallet to be transported away from the movable platform; and the movable platform is configured to move the first station back to the first position to accept an additional pallet with additional battery cells for testing. . The system of, wherein:
claim 12 . The system of, further comprising identification tags included with the pallet and the additional pallet to track movement and results of the camera.
claim 12 . The system of, wherein the plurality of test stations include the first station and seven additional stations identical to the first station to simultaneously test additional ones of the battery cells.
a rotatable platform; a plurality of test stations spaced apart in a circle about the rotatable platform and configured to rotate with the rotatable platform; probes included with each of the plurality of test stations, the probes are vertically movable into cooperation with the battery cells and configured to inject gas into the battery cells; an infrared camera adjacent to the rotatable platform and configured to detect leakage of the gas out from within any of the battery cells; an input conveyor line in cooperation with the rotatable platform and configured to feed the battery cells to the rotatable platform; and an output conveyor line in cooperation with the rotatable platform to carry the battery cells away from the rotatable platform. . A system configured to test battery cells, the system comprising:
claim 15 . The system of, wherein each one of the plurality of test stations includes a heated backplate configured as a background radiation source for the infrared camera.
claim 15 . The system of, wherein the infrared camera includes a filter configured to block transmission of infrared radiation outside of a wavelength of 4-5 μm.
transporting pallets with the battery cells thereon to a rotatable platform including a plurality of test stations, the plurality of test stations including probes movable into cooperation with the battery cells and configured to inject gas into the battery cells; coupling the pallets the plurality of test stations; moving the probes into cooperation with openings defined by the battery cells; injecting gas through the probes and into the battery cells through the openings; rotating the rotatable platform to move the plurality of test stations and the battery cells to an infrared camera configured to detect leakage of the gas out from within any of the battery cells; and with the openings of the battery cells plugged by the probes, activating the infrared camera to detect leakage of the gas out from within any of the battery cells at areas apart from the openings and assessing structural integrity of the battery cells based on detection of the gas having leaked out from within of the battery cells. . A method for testing battery cells comprising:
claim 18 . The method of, moving the pallets with the battery cells thereon to the rotatable platform across an input conveyor line in cooperation with the rotatable platform, and moving the pallets with the battery cells thereon away from the rotatable platform across an output conveyor line in cooperation with the rotatable platform.
claim 18 . The method of, wherein the gas is a first gas, the method further comprising, subsequent to sealing the openings of the battery cells, activating the infrared camera to detect leakage of a second gas out from within the battery cells, the second gas is different from the first gas.
Complete technical specification and implementation details from the patent document.
The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
The present disclosure relates to systems and methods for in-line leak detection of battery cells.
Battery cells are used to power a wide variety of devices and systems. For example, battery cells are power sources for battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and hybrid electric vehicles (HEVs). Various types of battery cells may be used, such as cylindrical battery cells, for example. Each cell includes an outer case, which is sealed to prevent the contents thereof from exiting the cell. Battery cell manufacturing processes include quality control checks to ensure the integrity of each battery cell.
The present disclosure includes, in various features, a system configured to test battery cells. The system includes: a movable platform; a plurality of test stations movable by the movable platform, each one of the plurality of test stations configured to cooperate with a pallet on which the battery cells are seated, each one of the plurality of test stations including probes that are movable into cooperation with the battery cells and configured to inject gas into each one of the battery cells; and a camera adjacent to the movable platform and configured to detect leakage of the gas out from within any of the battery cells.
In further features, the movable platform is circular.
In further features, an input conveyor line configured to transport the pallet to the movable platform and an output conveyor line configured to transport the pallet away from the movable platform after the battery cells are scanned by the camera.
In further features, each one of the plurality of test stations includes an entry gate and an exit gate spaced apart to accommodate the pallet therebetween, each one of the entry gate and the exit gate is configured to be opened and closed to permit transport of the pallet to and from the plurality of test stations.
In further features, the probes are movable vertically.
In further features, the gas is carbon dioxide.
In further features, the camera is an infrared camera including a filter configured to block transmission of infrared radiation outside of a wavelength range of 4-5 μm.
In further features, each one of the plurality of test stations further includes a back plate on a side of the pallet opposite to the camera, the back plate configured as a background radiation source for the camera and configured to be heated to a temperature of 10° C.-30° C. greater than an ambient temperature.
In further features, a pump is configured to pump the gas through the probes to the battery cells at a pressure of no greater than 1 psi.
In further features, the gas injected into the battery cells is a first gas injected prior to addition of an electrolyte within the battery cells; and the camera is further configured to detect leakage of a second gas out from within any of the battery cells subsequent to installation of an anode, a cathode, and an electrolyte, the second gas is different from the first gas.
In further features, the camera is an infrared camera including a filter configured to block transmission of infrared radiation outside of a wavelength range of 5-12 μm to detect the second gas.
In further features, the movable platform is configured to move a first station of the plurality of test stations to a first position at which a first pallet with a first group of the battery cells thereon is coupled to the first station between an entry gate and an exit gate of the first station, the battery cells devoid of an electrolyte; the movable platform is configured to move the first station to a second position at which a carrier is configured to move the probes into contact with the battery cells and a pump is configured to pump gas through the probes into the battery cells; the movable platform is configured to move the first station to a third position at which the probes remain in contact with the battery cells and the battery cells remain filled with the gas; the movable platform is configured to move the first station to a fourth position at which the camera is configured to scan the battery cells for leakage of the gas out from within the battery cells, and the carrier is configured move the probes away from contacting the battery cells after the camera has scanned the battery cells for leakage of the gas; the movable platform is configured to move the first station to a fifth position at which the exit gate is configured to open to permit the pallet to be transported away from the movable platform; and the movable platform is configured to move the first station back to the first position to accept an additional pallet with additional battery cells for testing.
In further features, identification tags are included with the pallet and the additional pallet to track movement and results of the camera.
In further features, the plurality of test stations include the first station and seven additional stations identical to the first station to simultaneously test additional ones of the battery cells.
The present disclosure also includes, in various features, a system configured to test battery cells, the system comprising: a rotatable platform; a plurality of test stations spaced apart in a circle about the rotatable platform and configured to rotate with the rotatable platform; probes included with each of the plurality of test stations, the probes are vertically movable into cooperation with the battery cells and configured to inject gas into the battery cells; an infrared camera adjacent to the rotatable platform and configured to detect leakage of the gas out from within any of the battery cells; an input conveyor line in cooperation with the rotatable platform and configured to feed the battery cells to the rotatable platform; and an output conveyor line in cooperation with the rotatable platform to carry the battery cells away from the rotatable platform.
In further features, each one of the plurality of test stations includes a heated backplate configured as a background radiation source for the infrared camera.
In further features, the infrared camera includes a filter configured to block transmission of infrared radiation outside of a wavelength of 4-5 μm.
The present disclosure also includes, in various features, a method for testing battery cells. The method includes: transporting pallets with the battery cells thereon to a rotatable platform including a plurality of test stations, the plurality of test stations including probes movable into cooperation with the battery cells and configured to inject gas into the battery cells; coupling the pallets the plurality of test stations; moving the probes into cooperation with openings defined by the battery cells; injecting gas through the probes and into the battery cells through the openings; rotating the rotatable platform to move the plurality of test stations and the battery cells to an infrared camera configured to detect leakage of the gas out from within any of the battery cells; and with the openings of the battery cells plugged by the probes, activating the infrared camera to detect leakage of the gas out from within any of the battery cells at areas apart from the openings and assessing structural integrity of the battery cells based on detection of the gas having leaked out from within of the battery cells.
In further features, the method includes moving the pallets with the battery cells thereon to the rotatable platform across an input conveyor line in cooperation with the rotatable platform, and moving the pallets with the battery cells thereon away from the rotatable platform across an output conveyor line in cooperation with the rotatable platform.
In further features, the gas is a first gas, the method further including, subsequent to sealing the openings of the battery cells, activating the infrared camera to detect leakage of a second gas out from within the battery cells, the second gas is different from the first gas.
Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
In the drawings, reference numbers may be reused to identify similar and/or identical elements.
The present disclosure is directed to systems and methods for in-line leak detection of battery cells. The systems and methods may be used to test any suitable battery cells configured to power any suitable device. The battery cells may cylindrical battery cells, for example. The battery cells may be configured to power any suitable device, such as a vehicle. With respect to vehicles, the battery cells may be configured to power battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), or hybrid electric vehicles (HEVs), for example. The battery cells may be configured for any other suitable non-automotive use as well. The systems and methods of the present disclosure are thus applicable to automotive and non-automotive applications as well.
The battery cells may be manufactured using any suitable manufacturing process. Exemplary manufacturing processes include sealing one or more components of an external casing together, such as by welding or otherwise securing a cover to case. The cover may be sealed prior to addition of an electrolyte, for example. The present disclosure provides for systems and methods for testing the integrity of the battery cells, such as the integrity of the seal of the cover. The testing may be performed prior to the introduction of the electrolyte by injecting a trace gas (such as carbon dioxide) into the battery cells, and then scanning the battery cells for leakage of the gas with any suitable sensor. Suitable sensors include an infrared camera configured to detect carbon dioxide. The systems and methods of the present disclosure are configured to scan for leaks in a very large number of battery cells in-line during manufacturing of the battery cells. For example, the systems and methods of the present disclosure are configured to scan at least 1,800 battery cells per hour. Subsequent to the introduction of the electrolyte, the present disclosure is also configured to perform in-line scans of the battery cells for any potential electrolyte leakage.
1 FIG. 10 10 20 10 22 20 22 20 10 30 20 32 20 20 10 illustrates an exemplary battery cell test systemin accordance with the present disclosure. The systemgenerally includes a movable platform, which may take the form of a rotatable base as illustrated or any other transport device or system configured to transport battery cells within the system. A motoris included and configured to move the movable platform. The motormay be configured to rotate the movable platformin the example illustrated. The systemincludes an input conveyor lineconfigured to transport batteries to the movable platform, and an output conveyor lineconfigured to transport batteries from the movable platform. As described herein, the movable platformpermits in-line battery inspection and testing, which enhances the process of assembling and inspecting batteries. The systemis configured to process 1,800 battery cells per hour, for example.
10 40 40 210 210 1 2 FIGS.and 3 FIG. Batteries are transported through the systemon pallets, or any other suitable movable platforms. The palletsmay be sized and shaped to carry any suitable number of batteries, such as three cylindrical battery cellsas illustrated in the examples of.illustrates an exemplary battery cell, which will be described further herein.
10 210 20 20 20 20 50 50 50 50 50 50 50 50 50 50 20 1 FIG. The systemincludes a plurality of test stations for testing the battery cells. The test stations are mounted to the movable platform, and moved with the rotatable platform. In the example illustrated in, the test stations rotate with the movable platform. The movable platformmay include eight test stations: a first test stationA; a second test stationB; a third test stationC; a fourth test stationD; a fifth test stationE; a sixth test stationF; a seventh test stationG; and an eighth test stationH. The test stationsA-H are evenly spaced apart about the rotatable platform, which in the example illustrated is a circular turntable.
20 22 50 50 50 50 50 50 50 50 50 50 20 22 20 50 50 50 50 1 FIG. Rotation of the movable platformby the motormoves the test stationsA-H to different test positions. In the example of: the first test stationA is at a first test position A; the second test stationB is at a second test position B; the third test stationC is at a third test position C; the fourth test stationD is at a fourth test position D; the fifth test stationE is at a fifth test position E; the sixth test stationF is at a sixth test position F; the seventh test stationG is at a seventh test position G; and the eighth test stationH is at an eight test position H. The movable platformis rotatable by the motorcounter-clockwise in 45° increments. Thus, the movable platformis rotatable to move the first test stationA from the first position A to the second position B, move the second test stationB from the second position B to the third position C, etc. The other test stationsB-H are likewise movable with the platform to the different test positions A-H.
50 50 50 50 50 50 50 60 62 40 50 60 62 40 210 50 60 60 62 40 50 20 50 50 50 40 40 210 40 42 2 FIG. The test stationsA-H are identical to each other, or substantially identical.illustrates the first test stationA, which will now be described in further detail. The description of the first test stationA also applies to the test stationsB-H. The first test stationA includes an entry gateand an exit gate, each of which are movable to control entry and exit of one of the palletsinto cooperation with the first test stationA. For example, with the entry gateopen and the exit gateclosed, the palletcarrying three of the battery cellsmay be transported to the first test stationA. The entry gateis then closed to secure the pallet between the entry gateand the exit gate. As a result, the palletwill rotate with the first test stationA as the movable platformrotates the first test stationA to the different positions A-H. Each one of the other test stationsA-H is configured to cooperate with a different palletto move the palletswith battery cellsthereon to the different positions A-H. Each one of the palletsincludes an identification tag, such as an RF ID tag or any other suitable tracking tag or other tracking feature.
50 70 72 72 70 74 72 80 80 82 90 90 82 80 210 80 72 210 74 The first test stationA further includes a towerto which is mounted a carrier. The carrieris movable vertically along the towerby a pneumatic cylinder, or any other suitable actuation device. Attached to the carrierare a plurality of probes. Each probeextends from a housing, which is in fluid communication with a pumpand a gas source. The pumpis configured to pump any suitable gas to the housingsat any suitable pressure (such as 1 psi, for example) and through the probesto the battery cellsas described herein. Any suitable gas may be used, such as carbon dioxide. The probesare vertically movable by the carrierto and away from the battery cells. The pneumatic cylinderis configured to move vertically 100 mm, or about 100 mm.
10 110 210 110 110 110 210 50 50 120 40 210 120 210 110 210 110 120 120 110 210 120 2 2 1 FIG. The systemfurther includes a camera, which is any suitable sensor configured to detect trace gas (such as carbon dioxide, CO) emanating from within the battery cell. The camerais positioned about the movable platform. In the example of, the camerais positioned at station D. The cameramay be configured as an infrared camera including a filter configured to block transmission of infrared radiation outside of a wavelength of 4-5 μm in order to detect any trace gas, such as CO, emanating from within the battery cell. Each test stationA-H further includes a back platebehind the palletwith the battery cells. At test station D, the back platewill be on a side of the battery cellsopposite to the camera. Thus, the battery cellswill be between the cameraand the back plate. The back plateis configured to be heated above ambient temperature to a temperature of 10° C.-30° C. greater than ambient. The camerais configured to capture middle wavelength infrared (MWIR) images of the battery cellsusing the back plateas a background panel, as described further herein.
3 FIG. 210 210 10 210 212 214 212 216 214 220 220 210 10 216 210 220 10 220 illustrates an exemplary battery cell. The battery cellis configured as a cylindrical cell. The battery cell test systemmay be configured to assess the integrity of any other suitable battery cell as well. The battery cellgenerally includes a caseand a cover(or lid) that is sealed to the casewith any suitable seal. At a center of the coveris a center aperture. The center aperturemay be configured as a fill port, such as for filling the battery cellwith an electrolyte. Prior to filling the cell with the electrolyte, the systemis configured to test the integrity of the sealas described herein. After the battery cellis filled with the electrolyte (and an anode and cathode is seated therein), the center apertureis sealed closed. The systemis further configured to assess structural integrity of the sealed center apertureas well, as described herein.
10 150 10 150 22 22 20 150 50 50 80 220 150 90 80 220 110 216 150 60 62 The systemfurther includes a control module, which is configured to control the system, or any other suitable battery cell test system to provide the described functionality. For example, the control moduleis in communication with the motorto operate the motorto rotate the movable platformas described. The control moduleis further in communication with the each one of the test stationsA-H to move the probesto and from the center aperturesas described herein. The control moduleis configured to operate the pumpto pump gas through the probesand through the center apertures, and configured to operate the camerato detect any gas that has leaked through the sealor at any other relevant location. The control moduleis further configured to control operation of the entry gateand the exit gate.
150 90 220 220 210 210 150 110 210 80 110 In some applications the control modulemay be further configured to operate the pump, or any other suitable vacuum generation device, to generate a vacuum at a seal closing the center apertureto test whether the seal at the center apertureis sufficient to retain electrolyte and other contents of the battery cellwithin the battery cell. In such applications, the control moduleis configured to operate the camerato identify any electrolyte or other vapors, gases, etc. that have been pulled out from within the battery cellby a vacuum created by the probes. The camerawill include a filter configured to block transmission of infrared radiation outside of a wavelength range of 5-12 μm.
150 20 50 50 310 10 310 410 510 610 710 50 50 50 4 FIG. The control modulemay be configured to rotate the movable platformsuch that each test stationA-H spends a predetermined amount of time at each position A-H, such as 5 seconds at each position A-H and 1 second in transition between the positions A-H.illustrates an exemplary methodfor operation of the system. The method, as well as the methods,,, andset forth herein will now be primarily described with reference to the first test stationA, but the methods equally apply to the test stationsB-H as well.
312 310 150 22 50 314 150 62 310 60 40 316 150 30 40 210 60 62 40 210 212 214 212 216 220 210 At blockof the method, the control moduleoperates the motorto rotate the first test stationA to the first position A, and at blockthe control moduleoperates any suitable motor or actuation mechanism to close the exit gate. At this stage in the method, the entry gatewill be open from the release of a previous pallet. At block, the control moduleoperates the input conveyor lineto move the palletcarrying the battery cellspast the open entry gateto the first position A. The closed exit gateprevents the palletfrom traveling past the first position A. At this stage, the battery cellswill each include the caseand the coversealed to the caseat the seal. The center aperturewill be open and no electrolyte will be in the battery cells.
318 40 50 320 150 60 60 40 60 62 40 50 50 322 42 40 42 210 40 42 216 216 324 150 326 150 74 72 80 220 80 310 330 324 310 326 324 330 At block, the palletarrives at the first test stationA positioned at the first position A. At block, the control moduleis configured to close the entry gatein any suitable manner, such as by actuating a motor in cooperation with the entry gate. With the palletbetween the closed entry gateand the closed exit gate, the palletis coupled with the first test stationA to rotate with the first test stationA from the first position A to the fifth station E as described herein. At block, the identification tagof the palletis read by any suitable scanning device. The identification tagprovides various information regarding the battery cellson the pallet. For example, the identification tagmay identify the type of battery cell, the type of seal, date of the seal, part and lot number, end use, manufacture date, etc. If at blockvarious predetermined prerequisites are met, the control moduleadvances the method to blockwhere the control moduleoperates the pneumatic cylinderto lower the carrierand the probesto seal against the center apertures. After the probesare lowered, the methodproceeds to blockwhere the cycle of the first position A is complete. If the predetermined prerequisites are not met at block, the methodskips blockand proceeds from blockdirectly to block.
5 FIG. 410 10 412 150 22 20 50 414 150 80 220 80 416 150 90 80 210 220 420 150 22 50 210 2 illustrates another methodin accordance with the present disclosure for operating the systemat the second position B. At block, the control moduleoperates the motorto rotate the movable platformto advance the first test stationA from the first position A to the second position B. At block, the control modulechecks whether the probesare still extended to the center apertures. If the probesare still extended, at blockthe control moduleoperates the pumpto pump any suitable gas (such as CO) through the probesand into the battery cellsthrough the open center apertures. At block, the operation cycle at the second position B is complete. From the second position B, the control moduleis configured to operate the motorto rotate the first test stationA to the third position C. At the third position C, no action is taken on the battery cells.
6 FIG. 510 10 512 150 20 50 110 514 150 110 210 210 80 220 220 150 110 210 illustrates a methodfor operation of the systemat the fourth position D. At block, the control moduleis configured to operate the motor to rotate the movable platformto move the first test stationA from the third position C to the fourth position D. As explained above, the camerais mounted at the fourth position D. At block, the control moduleis configured to operate the camerato inspect the battery cellfor leakage of the gas pumped into the battery cellsthrough the probes, which are still at the center apertureto close the center aperture. The control moduleoperates the camerato capture one or more infrared images of each of the battery cells.
516 150 150 150 216 210 212 214 150 110 120 210 210 216 150 150 80 210 210 216 2 At block, after capturing, and optionally saving, middle wavelength infrared (MWIR) images at any suitable storage device of the control module(or associated with the control module) the control moduleis configured to analyze the captured infrared images to ascertain whether or not a gas leak is present at the sealor at any other relevant location of the battery cell(such as at the caseor the cover). In a non-limiting example, an image analysis module of the control moduleexamines each infrared image captured by the camerato evaluate MWIR waves passing between the back plate, which is heated, and the battery cell(e.g., along an upper edge of the battery cellat the seal. The image analysis module of the control modulemay use any suitable gas cloud modeling algorithm, for example, to locate one or more aberrations, if any, within the imaged MWIR waves. The control moduleis configured to determine that each aberration is caused by compressed COgas (or any other suitable gas injected by the probesinto the battery cells) leaking from the battery cell(e.g., leaking from the sealthat has cracked or otherwise had its integrity compromised).
516 150 516 518 518 150 110 520 42 520 510 522 80 220 210 At block, the control moduledetermines whether a gas leak has been detected, or a predetermined inspection period has elapsed without detection of a leak. The predetermined inspection period may be 4.5 seconds, for example, or any other suitable inspection period. Once a gas leak has been detected or the predetermined inspection period has elapsed, the control module proceeds from blockto block. At block, the control moduleends the inspection by the camera, and at blockthe results of the inspection are recorded and associated with the identification tag. From block, the methodproceeds to blockwhere the control module operates the pneumatic cylinder to raise the probesout from cooperation with the center apertureof the battery cell.
510 150 610 10 612 150 22 50 614 150 616 150 42 150 618 150 74 72 80 210 7 FIG. From the method, the control moduleproceeds to the methodof, which controls operation of the systemat the fifth position E. At block, the control moduleoperates the motorto rotate the first test stationA to the fifth position E. At block, the control modulereads the identification tag using any suitable scanning device. At block, the control modulechecks the data associated with the identification tagfor completeness (e.g., completeness of the results of the camera inspection). If the data is complete, the control moduleproceeds to block, where the control moduleis configured to operate the pneumatic cylinderto raise the carrier, which raises the probesout from cooperation with the battery cells.
80 150 62 620 62 32 40 20 10 40 10 150 60 40 210 628 150 22 20 50 40 210 After the probesare raised, the control moduleis configured to open the exit gateat block. With the exit gateopen, the output conveyor lineis able to pull the palletoff of the movable platformand out of the systemto a subsequent manufacturing/test location. After the pallethas exited the system, the control moduleopens the entry gatein preparation for receiving an additional palletwith additional battery cellsfor inspection. At block, operation at the fifth station E is complete, and the control moduleis configured to operate the motorto rotate the platformin 45° increments through the sixth station F, the seventh station G, and the eight station H. No operations take place at the sixth station F, the seventh station G, or the eighth station H. From the eighth station H, the first test stationA is rotated back to the first position A where another palletis received for inspection of battery cellsthereon.
8 FIG. 710 10 712 150 20 50 50 110 150 710 714 150 50 50 150 110 710 716 150 10 714 150 718 150 22 710 712 illustrates an overall methodfor operation of the systemby the control module. At block, the control modulemaintains the movable platform, and the test stationsA-H, at each position A-H for a predetermined time period for the processing at each station to take place, such as inspection by the cameraat the fourth position D. The predetermined time period may be 5 seconds, for example. Once the predetermined time period has expired as measured by the control module, the methodproceeds to block, wherein the control moduledetermines whether processing at all of the test stationsA-H has completed. For example, the control modulewill determine whether the inspection by the camerais complete and whether the injection of gas at the first position A is complete. If all stations are not complete, the methodproceeds to blockwhere an over cycle warning is issued by the control module. In response to the warning, an operator may inspect the systemfor a failure. If at blockthe control moduledetermines that all stations are complete, at blockthe control modulewill operate the motorto index the movable platform 45°. Once the index is complete, the methodreturns to block.
10 310 610 216 220 210 80 210 216 220 110 150 110 216 220 210 The systemand corresponding methods-may also be configured to detect leakage of electrolyte and electrolyte-related vapors out through the sealor the center apertureafter the electrolyte has been added to the battery cells. The operation of the probesis modified to create a vacuum attempting to draw electrolyte-related vapors out from within the battery cellsthrough the sealor a seal at the center aperture. The camerais modified with a filter configured to block transmission of infrared radiation outside of a wavelength range of 5-12 μm to detect the electrolyte-related vapors. At the fourth position D, the control moduleoperates the camerato scan for any electrolyte-related vapors that may be passing through the sealor the sealed center aperture. Any of the battery cellsexperiencing leaks may be identified and processed accordingly.
The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and/or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.
Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “engaged,” “coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “disposed.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship can be a direct relationship where no other intervening elements are present between the first and second elements, but can also be an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
In the figures, the direction of an arrow, as indicated by the arrowhead, generally demonstrates the flow of information (such as data or instructions) that is of interest to the illustration. For example, when element A and element B exchange a variety of information but information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for, or receipt acknowledgements of, the information to element A.
In this application, including the definitions below, the term “module” or the term “controller” may be replaced with the term “circuit.” The term “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.
The module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that are connected to a local area network (LAN), the Internet, a wide area network (WAN), or combinations thereof. The functionality of any given module of the present disclosure may be distributed among multiple modules that are connected via interface circuits. For example, multiple modules may allow load balancing. In a further example, a server (also known as remote, or cloud) module may accomplish some functionality on behalf of a client module.
The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects. The term shared processor circuit encompasses a single processor circuit that executes some or all code from multiple modules. The term group processor circuit encompasses a processor circuit that, in combination with additional processor circuits, executes some or all code from one or more modules. References to multiple processor circuits encompass multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit encompasses a single memory circuit that stores some or all code from multiple modules. The term group memory circuit encompasses a memory circuit that, in combination with additional memories, stores some or all code from one or more modules.
The term memory circuit is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).
The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.
The computer programs include processor-executable instructions that are stored on at least one non-transitory, tangible computer-readable medium. The computer programs may also include or rely on stored data. The computer programs may encompass a basic input/output system (BIOS) that interacts with hardware of the special purpose computer, device drivers that interact with particular devices of the special purpose computer, one or more operating systems, user applications, background services, background applications, etc.
The computer programs may include: (i) descriptive text to be parsed, such as HTML (hypertext markup language), XML (extensible markup language), or JSON (JavaScript Object Notation) (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. As examples only, source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language 5th revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.
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September 18, 2024
March 19, 2026
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